EP1882273B1 - High voltage silicon carbide mos-bipolar devices having bi-directional blocking capabilities and methods of fabricating the same - Google Patents

High voltage silicon carbide mos-bipolar devices having bi-directional blocking capabilities and methods of fabricating the same Download PDF

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Publication number
EP1882273B1
EP1882273B1 EP06750425.8A EP06750425A EP1882273B1 EP 1882273 B1 EP1882273 B1 EP 1882273B1 EP 06750425 A EP06750425 A EP 06750425A EP 1882273 B1 EP1882273 B1 EP 1882273B1
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sic
region
substrate
voltage blocking
silicon carbide
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German (de)
English (en)
French (fr)
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EP1882273A2 (en
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Sei-Hyung Ryu
Jason R. Jenny
Mrinal K. Das
Hudson Mcdonald Hobgood
Anant K. Agarwal
John W. Palmour
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Wolfspeed Inc
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Cree Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
    • H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
    • H01L29/68—Types of semiconductor device ; Multistep manufacturing processes therefor controllable by only the electric current supplied, or only the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched
    • H01L29/70—Bipolar devices
    • H01L29/72—Transistor-type devices, i.e. able to continuously respond to applied control signals
    • H01L29/739—Transistor-type devices, i.e. able to continuously respond to applied control signals controlled by field-effect, e.g. bipolar static induction transistors [BSIT]
    • H01L29/7393—Insulated gate bipolar mode transistors, i.e. IGBT; IGT; COMFET
    • H01L29/7395—Vertical transistors, e.g. vertical IGBT
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
    • H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
    • H01L29/66007—Multistep manufacturing processes
    • H01L29/66053—Multistep manufacturing processes of devices having a semiconductor body comprising crystalline silicon carbide
    • H01L29/66068—Multistep manufacturing processes of devices having a semiconductor body comprising crystalline silicon carbide the devices being controllable only by the electric current supplied or the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched, e.g. three-terminal devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
    • H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
    • H01L29/66007—Multistep manufacturing processes
    • H01L29/66075—Multistep manufacturing processes of devices having semiconductor bodies comprising group 14 or group 13/15 materials
    • H01L29/66227—Multistep manufacturing processes of devices having semiconductor bodies comprising group 14 or group 13/15 materials the devices being controllable only by the electric current supplied or the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched, e.g. three-terminal devices
    • H01L29/66234—Bipolar junction transistors [BJT]
    • H01L29/66325—Bipolar junction transistors [BJT] controlled by field-effect, e.g. insulated gate bipolar transistors [IGBT]
    • H01L29/66333—Vertical insulated gate bipolar transistors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
    • H01L29/02—Semiconductor bodies ; Multistep manufacturing processes therefor
    • H01L29/12—Semiconductor bodies ; Multistep manufacturing processes therefor characterised by the materials of which they are formed
    • H01L29/16—Semiconductor bodies ; Multistep manufacturing processes therefor characterised by the materials of which they are formed including, apart from doping materials or other impurities, only elements of Group IV of the Periodic Table
    • H01L29/1608—Silicon carbide

Definitions

  • This invention relates to power semiconductor devices and related methods of fabricating power semiconductor devices and, more particularly, to high voltage silicon carbide devices and related methods of fabricating high voltage silicon carbide devices.
  • Power devices are widely used to carry large currents and support high voltages. Modern power devices are generally fabricated from monocrystalline silicon semiconductor material. One type of power device is the thyristor. A thyristor is a bistable power semiconductor device that can be switched from an off-state to an on-state, or vice versa. Power semiconductor devices, such as thyristors, high-power bipolar junction transistors (“HPBJT”), or power metal oxide semiconductor field effect transistors (“MOSFET”), are semiconductor devices capable of controlling or passing large amounts of current and blocking high voltages.
  • HPBJT high-power bipolar junction transistors
  • MOSFET power metal oxide semiconductor field effect transistors
  • Silicon bipolar transistors have, conventionally, been used for high power applications in motor drive circuits, appliance controls, robotics and lighting ballasts. This is because bipolar transistors can be designed to handle relatively large current densities, for example, in the range of 200 to 50 A/cm 2 and support relatively high blocking voltages in the range of 500-2500V.
  • Bipolar transistors are current controlled devices that typically require relatively large base control currents, typically one fifth to one tenth of the collector current, to maintain the transistor in an on-state mode. Proportionally larger base currents can be expected for applications that also require high speed turn-off. Because of the large base current demands, the base drive circuitry for controlling turn-on and turn-off is relatively complex and expensive. Bipolar transistors may also be vulnerable to premature breakdown if a high current and high voltage are simultaneously applied to the device, as commonly required in inductive power circuit applications.
  • Silicon power MOSFETs address this base drive problem.
  • the gate electrode provides turn-on and turn-off control upon the application of an appropriate gate bias.
  • turn-on in an n-type enhancement MOSFET occurs when a conductive n-type inversion layer is formed in the p-type channel region in response to the application of a positive gate bias.
  • the inversion layer electrically connects the n-type source and drain regions and allows for majority carrier conduction between source and drain.
  • the power MOSFET's gate electrode is separated from the conducting channel region by an intervening insulating layer, typically silicon dioxide. Because the gate is insulated from the channel region, little gate current is required to maintain the MOSFET in a conductive state or to switch the MOSFET from an on-state to an off-state or vice-versa. The gate current is kept small during switching because the gate forms a capacitor with the MOSFET's channel region. Thus, only charging and discharging current (“displacement current”) is typically required during switching. Because of the high input impedance associated with the insulated-gate electrode, minimal current demands are placed on the gate and the gate drive circuitry can be easily implemented.
  • intervening insulating layer typically silicon dioxide.
  • power MOSFETs can be made orders of magnitude faster than that of bipolar transistors.
  • power MOSFETs can be designed to simultaneously withstand high current densities and the application of high voltages for relatively long durations, without encountering the destructive failure mechanism known as "second breakdown.”
  • Power MOSFETs can also easily be paralleled, because the forward voltage drop of power MOSFETs increases with increasing temperature, thereby promoting an even current distribution in parallel connected devices.
  • MOSFETs power MOSFETs
  • a MOSFET's operating forward current density is typically limited to relatively low values, for example, in the range of 40-50 A/cm 2 , for a 600 V device, as compared to 100-120 A/cm 2 for the bipolar transistor for a similar on-state voltage drop.
  • IGBT Insulated Gate Bipolar Transistor
  • the IGBT combines the high impedance gate of the power MOSFET with the small on-state conduction losses of the power bipolar transistor. Because of these features, the IGBT has been used extensively in inductive switching circuits, such as those required for motor control applications. These applications require devices having wide forward-biased safe-operating-area (FBSOA) and wide reverse-biased safe-operating-area (RBSOA).
  • FBSOA forward-biased safe-operating-area
  • RSOA reverse-biased safe-operating-area
  • Silicon carbide (SiC) devices have also been proposed and used as power devices. Such devices include power MOSFETs such as are described in United States Patent No. 5,506,421 . Similarly, silicon carbide Junction Field Effect Transistors (JFETs) and Metal-Semiconductor Field Effect Transistors (MESFETs) have also been proposed for high power applications. See United States Patent Nos. 5,264,713 and 5,270,554 .
  • Silicon carbide IGBTs have also been described in United States Patent No. 5,831,288 and United States Patent No. 6,121,633 .
  • IGBTs Insulated Gate Bipolar Transistors
  • these high voltage devices are typically formed using a lightly doped epitaxial layer (n or p type) on a highly doped n-type conductivity silicon carbide substrate having a thickness of from about 300 to about 400 ⁇ m.
  • Low resistivity p-type silicon carbide substrates may not be available as a result of the available acceptor species (Aluminum and Boron) having deep energy levels that may result in carrier freeze out.
  • the exclusive use of n-type substrates may limit the polarity of available high voltage devices. For example, only p-channel Insulated Gate Bipolar Transistors (IGBTs) may be available. In addition, the available devices may only be capable of blocking voltages in one direction.
  • IGBTs Insulated Gate Bipolar Transistors
  • present silicon carbide IGBTs may require more complex gate drive circuitry with level shifting components and result in more complex power circuits as a result of the structure of IGBTs, the electrical characteristics of silicon carbide and the limitations in fabrication of highly doped p-type silicon carbide substrates.
  • a planar edge termination structure may be formed or an edge beveling process may be used to reduce the likelihood of premature breakdown at the edges of the device.
  • Forming planar edge termination structures on a backside of the device may be difficult and costly to implement as extensive processing may be needed after removal of the 300 to 400 ⁇ m thick n-type substrate.
  • Edge beveling may include etching through the substrate or grinding/polishing the sidewalls of the device, which may also be difficult because the voltage blocking epitaxial layers are generally much thinner than the substrate.
  • US-5,712,502 concerns a semiconductor component with a vertical extension of a depletion zone dependent upon an applied blocking voltage.
  • a junction termination for an active area uses a semiconductor doped oppositely to the semiconductor region accommodating the depletion zone of the active area. The junction termination is arranged immediately adjacent around the active area.
  • US-5,313,092 concerns a semiconductor device having a vertical arrangement, with a pn junction formed inside a first semiconductor substrate that is joined to a second semiconductor substrate.
  • the periphery of the first semiconductor substrate is configured in an inverted mesa structure.
  • US 2005029557 discloses a high-breakdown-voltage semiconductor device comprising a high-resistance semiconductor layer, trenches formed on the surface thereof in a longitudinal plane shape and in parallel.
  • WO2004020706 discloses a method to fabricate SiC wafers from lightly doped n- or p-type crystals and a semiconductor structure using a lightly doped wafer as n-drift zone.
  • the present invention provides a high voltage silicon carbide (SiC) device in line with claim 1 and a method of fabricating a high voltage SiC device in accordance with claim 18.
  • the embodiments provide high voltage silicon carbide (SiC) devices and methods of fabricating high voltage SiC devices that include a SiC insulated gate bipolar transistor (IGBT) comprising a voltage blocking substrate as a drift region of the IGBT, a planar edge termination structure at a first face of the voltage blocking substrate and surrounding an active region of the IGBT and a beveled edge termination structure extending through a second face of the voltage blocking substrate opposite the first face of the voltage blocking substrate.
  • IGBT SiC insulated gate bipolar transistor
  • the voltage blocking substrate is a boule grown substrate.
  • the voltage blocking substrate may be a 4H-SiC high purity substrate having a carrier concentration no greater than about 1.0 x 10 15 cm -3 .
  • the voltage blocking substrate may have a thickness of greater than about 100 ⁇ m.
  • the voltage blocking substrate may comprise an n-type or a p-type SiC substrate.
  • Some embodiments provide high voltage silicon carbide (SiC) devices and methods of fabricating high voltage SiC devices that include a first SiC layer having a first conductivity type on a first surface of a voltage blocking SiC substrate having a second conductivity type, a first region of SiC at a second surface of the substrate and having the first conductivity type, a second region of SiC in the first region of SiC, the second region having the first conductivity type and having a carrier concentration higher than a carrier concentration of the first region, a third region of SiC in the first region of SiC, the third region having the second conductivity type, an insulator layer on the substrate, a gate electrode on the insulator layer and adjacent the first and third regions of SiC, a first contact on the second and third regions of SiC and a second contact on the first SiC layer.
  • SiC silicon carbide
  • the device further includes a planar edge termination structure at a first face of the substrate and a beveled edge termination structure at a second face of the substrate opposite the first face of the substrate.
  • the voltage blocking substrate is a boule grown substrate.
  • the voltage blocking substrate may comprise a 4H-SiC high purity substrate having a carrier concentration no greater than about 1.0 x 10 15 cm -3 .
  • the voltage blocking substrate may have a thickness of greater than about 100 ⁇ m.
  • the first conductivity type may comprise p-type SiC and the second conductivity type may comprise n-type SiC.
  • the first conductivity type may comprise n-type SiC and the second conductivity type may comprise p-type SiC.
  • the first SiC layer has a thickness of from about 0.1 to about 20 ⁇ m.
  • the first SiC layer may have a carrier concentration of from about 1X101 6 to about 1X10 21 cm -3 .
  • the first SiC region may have a carrier concentration of from about 1X10 15 to about 5X10 19 cm -3 and/or a depth of from about 0.3 to about 2.0 ⁇ m.
  • the second SiC region may have a carrier concentration of from about 5X10 17 to about 1X10 21 cm -3 and/or a depth of from about 0.1 to about 2.0 ⁇ m.
  • the third SiC region may have a carrier concentration of from about 5X10 17 to about 1X10 21 cm -3 and/or a depth of from about 0.1 to about 1.5 ⁇ m.
  • the device further includes fourth regions of SiC at the second surface of the substrate and having the second conductivity type.
  • the fourth regions of SiC provide a planar edge termination structure at a first face of the substrate.
  • the fourth SiC regions may have a carrier concentration of from about 5X10 17 to about 1X10 21 cm -3 and/or a depth of from about 0.1 to about 2.0 ⁇ m.
  • first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
  • relative terms such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in the Figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower”, can therefore, encompass both an orientation of “lower” and “upper,” depending on the particular orientation of the figure.
  • Embodiments of the present invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments of the present invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the present invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle will, typically, have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region.
  • a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place.
  • the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region of a device and are not intended to limit the scope of the present invention.
  • Embodiments of the present invention are described with reference to a particular polarity and/or conductivity type for various layers/regions. However, as will be appreciated by those of skill in the art, the polarity of the regions/layers may be inverted to provide an opposite polarity device.
  • first conductivity type and second conductivity type refer to opposite conductivity types such as n or p-type, however, each embodiment described and illustrated herein includes its complementary embodiment as well.
  • high voltage power devices are provided on voltage blocking substrates.
  • Voltage blocking and/or carrier injecting pn junctions may be formed by growth of epilayers and/or ion implantation. Because the removal of the n + substrate may no longer be required, a planar termination structure may be readily implemented.
  • an edge beveling process may also be simplified according to some embodiments of the present invention as the location of the pn blocking junctions ( i.e., between the voltage blocking substrate and the layer formed thereon) may be well defined and the voltage blocking layer (substrate) accounts for most of the thickness of the device.
  • high voltage devices may be provided on n-type and/or p-type silicon carbide substrates, which may increase the polarities available in high voltage devices as discussed further herein.
  • a "voltage blocking substrate” refers to an n-type or a p-type high purity silicon carbide substrate capable of providing a bi-directional voltage blocking layer for a high voltage device.
  • the voltage blocking substrate may be a 4H-SiC substrate having a carrier concentration of no greater than about 1.0 X 10 15 cm -3 and a thickness of greater than about 100 ⁇ m. The details with respect to the voltage blocking substrate and methods of fabricating the voltage blocking substrate are discussed in commonly assigned United States Patent publication no. 2006/130742 entitled Process for Producing Silicon Carbide Crystals Having Increased Minority Carrier Lifetimes, filed February 7, 2005.
  • Embodiments of the present invention are described herein with reference to Figure 1 , which is a cross-section of an insulated gate bipolar transistor (IGBT) structure having implanted regions in a voltage blocking substrate.
  • IGBT insulated gate bipolar transistor
  • implanted regions may be provided as epitaxial regions on the substrate. Accordingly, embodiments of the present invention are not limited to implantation in a substrate but may also include regions on a substrate or combinations thereof.
  • doped regions of silicon carbide may be formed through epitaxial growth and/or through implantation.
  • a p-type region of silicon carbide may be formed through epitaxial growth in the presence of a p-type dopant or through implantation of p-type dopants in an undoped, p-type or n-type epitaxial layer.
  • the structure that results from epitaxial growth differs from that that results from implantation.
  • the terms "epitaxial region or layer” and “implanted region or layer” structurally distinguish differing regions of silicon carbide.
  • a silicon carbide (SiC) voltage blocking substrate 10 is provided.
  • the polarity of the substrate 10 may be n-type or p- type SiC having a polytype of, for example, 3 C, 2H, 4H5 6H or 15R.
  • devices discussed according to embodiments of the present invention illustrated in Figure 1 include n-type SiC substrates 10.
  • the substrate 10 may be a high purity 4H SiC substrate having a carrier concentration of no greater than about 1.0 X 10 15 cm -3 and a thickness of greater than about 150 ⁇ m.
  • the substrate 10 has a first face 10B and a second face 10A, opposite the first face 10B.
  • the substrate 10 is a boule grown substrate.
  • Boule grown substrates are discussed in commonly assigned United States Patent publication no. 2005/082542, filed October 16, 2003 , entitled Methods of Forming Power Semiconductor Devices using Boule-Grown Silicon Carbide Drift Layers and Power Semiconductor Devices Formed Thereby.
  • a first layer of SiC 12 is provided at a second surface 10A of the substrate 10.
  • the first layer of SiC 12 may be a p-type or an n-type SiC epitaxial layer.
  • doped regions of silicon carbide may be formed through epitaxial growth and/or through implantation.
  • a p-type region of silicon carbide may be formed through epitaxial growth in the presence of a p-type dopant or through implantation of p-type dopants in an undoped, p-type or n-type epitaxial layer.
  • the structure that results from epitaxial growth differs from that that results from implantation.
  • the terms "epitaxial region or layer” and “implanted region or layer” structurally distinguish differing regions of silicon carbide.
  • the first layer of SiC 12 may be an p-type epitaxial layer provided on a n- type substrate 10.
  • the p-type SiC epitaxial layer 12 may have a carrier concentration of from about 1.0 X 10 16 to about 1.0 X 10 21 cm -3 and a thickness of from about 0.1 to about 20.0 ⁇ m.
  • the substrate may have a carrier concentration of less than about 1 X 10 15 cm -3 .
  • the pn junction between the first layer 12 and the substrate 10 may provide blocking capability when the device is in the off-state and carrier injection when the device is in the on-state.
  • a first region of SiC 14 is provided at a first face 10B of the substrate 10 and is of opposite conductivity type to the substrate 10.
  • the first region is an implanted region that provides a p-well or n-well depending on the polarity of the substrate 10.
  • the first region of SiC 14 may be provided as spaced apart portions when viewed in cross-section with a junction field effect transistor (JFET) region 30 between the spaced apart portions.
  • JFET junction field effect transistor
  • the first region of SiC 14 may have a carrier concentration of from about 1.0 X 10 15 to about 5.0 X 10 19 cm -3 and may extend into the substrate to a depth of from about 0.3 to about 2.0 ⁇ m.
  • the spacing between adjacent spaced apart portions of the first region of SiC 14 may be enough so that a neutral channel exists between the top MOS channel to the drift layer. This spacing may be reduced by introducing an implant in the JFET region 30 to increase the carrier concentration in the JFET region 30 between adjacent spaced apart portions of the first region of SiC 14. While the first region of SiC 14 is described herein as being a single region having spaced apart portions, the first region of SiC 14 may also be provided as spaced apart separate regions with a JFET region 30 between the separate regions.
  • second and third regions of SiC 18 and 20 of opposite conductivity type may be provided within the first region 14 and at the first face 10B of the substrate 10.
  • the second and third regions of SiC 18 and 20 may be provided as spaced apart portions when viewed in cross-section as illustrated in Figure 1 . While the second and third regions of SiC 18 and 20 are described herein as being single regions having spaced apart portions, the second and third regions of SiC 18 and 20 may also be provided as multiple spaced apart separate regions within respective first regions of SiC 14.
  • the second and third regions of SiC 18 and 20 are p + regions of SiC and n + regions of SiC, respectively.
  • p + " or "n + " refer to regions that are defined by higher carrier concentrations than are present in adjacent or other regions of the same or another layer or substrate.
  • p - " or "n - " refer to regions that are defined by lower carrier concentrations than are present in adjacent or other regions of the same or another layer or substrate.
  • the second region of SiC 18 may have carrier concentrations of from about 5.0 X 10 17 to about 1.0 X 10 21 cm -3 and may extend into the substrate to a depth of from about 0.1 to about 2.0 ⁇ m.
  • the second regions of SiC 18 may be implanted with p-type dopants, such as Al or B through ion implantation.
  • the third region of SiC 20 may have carrier concentrations of from about 5.0 X 10 17 to about 1.0 X 10 21 cm -3 and may extend into the substrate to a depth of from about 0.1 to about 1.5 ⁇ m.
  • the third regions of SiC 20 may be implanted with n-type dopants, such as nitrogen or phosphorous through ion implantation.
  • a planar edge termination structure is provided at the first face 10B of the substrate 10.
  • floating guard rings may be provided by fourth regions of SiC 16 in the substrate 10 of opposite conductivity type to the substrate 10 and surrounding the first region of SiC 14.
  • the fourth regions of SiC 16 may have carrier concentrations of from about 5.0 X 10 17 to about 1.0 X 10 21 cm -3 and may extend into the substrate to a depth of from about 0.1 to about 2.0 ⁇ m.
  • the fourth regions of SiC 16 may be formed at the same time as the second region of SiC 18.
  • the fourth regions of SiC 16 may be implanted with p-type dopants, such as Al or B through ion implantation.
  • a gate insulator layer 22 is provided on the substrate 10.
  • the gate insulator 22 may, for example, be an oxide, an oxynitride or an oxide-nitride-oxide structure.
  • the gate insulator 22 is an oxide that is formed and/or annealed in an NO and/or N 2 O environment.
  • the gate insulator may be formed as described in United States Patent No. 6,610,366 entitle "METHOD OF N 2 O ANNEALING AN OXIDE LAYER ON A SILICON CARBIDE LAYER," United States Patent No.
  • a gate electrode 26 is provided on the gate insulator layer 22 and disposed above the JFET region 30.
  • the gate electrode 26 may, for example, be n- type or p-type polysilicon, or refractory metals, such as Mo or W and/or metal suicides.
  • Ohmic contacts 24 and 28 are provided on the second and third regions of SiC 18 and 20 and the first layer of SiC 12, respectively.
  • the ohmic contacts 24 and 28 may provide emitter and collector contacts for an IGBT according to some embodiments of the present invention.
  • ohmic contacts to n + regions may be nickel (Ni) and ohmic contacts to p + regions may be aluminum (Al) based contacts, such Al/(Titanium (Ti)) contacts.
  • Ni nickel
  • Al aluminum
  • Ti titanium
  • Metal overlayer(s) may be provided on the ohmic contacts 24 and 28 and/or gate electrode 26.
  • the metal overlayer(s) may include, for example, gold, silver, aluminum, platinum and/or copper. Other suitable highly conductive metals may also be used for the overlayer(s). The presence of the overlayer(s) may provide a more suitable device for soldering and/or wire bonding as will be understood by those having skill in the art.
  • the edges of the device are beveled.
  • the edge beveling process is performed to provide a bevel edge termination structure.
  • pn blocking junctions may be provided between the second surface 10A of the substrate 10 and the first layer of SiC 12. Edge beveling is discussed in detail in Physics of Semiconductor Devices by S.M. Sze at pages 196-198 .
  • embodiments of the present invention are not limited to this configuration.
  • devices having opposite conductivity types may also be provided.
  • a device may be provided having a p-type SiC substrate 10, an n-type first layer of SiC 12 on the second surface 10A of the substrate 10, an n-type first region of SiC 14 at the first surface 10B of the substrate 10, an n + second region of SiC 18, a p + third region of SiC 20 and n fourth regions of SiC 16 without departing from the scope of the present invention.
  • devices according to some embodiments of the present invention may be provided on voltage blocking substrates capable of providing a bi-directional voltage blocking layer.
  • Providing devices on voltage blocking substrates may allow the provision of high voltage power devices having p-type or n-type conductivity substrates, which may increase the available polarity of such devices.
  • pn junctions between surfaces of the substrate and layers provided thereon may be more easily identifiable, which may allow provision of devices capable of blocking in multiple directions as discussed herein.
  • a first layer of SiC 12 is formed on a second surface 10A of a silicon carbide (SiC) voltage blocking substrate 10.
  • the SiC substrate 10 may be n- type or p-type silicon carbide.
  • the SiC substrate 10 of Figures 2A through 2H is a n-type SiC substrate.
  • the substrate 10 may be a high purity 4H SiC substrate having a carrier concentration of no greater than about 1.0 X 10 15 cm -3 and a thickness of greater than about 100 ⁇ m.
  • the voltage blocking substrate may be fabricated using methods discussed in commonly assigned United States Patent publication no. 2006/130742 entitled Process for Producing Silicon Carbide Crystals Having Increased Minority Carrier Lifetimes, filed February 7, 2005.
  • the first layer of SiC 12 may be a p-type or an n-type silicon carbide layer and may be grown on the second surface 10A of the substrate 10 or implanted in the second surface 10A of the substrate 10 without departing from the scope of the present invention. If the first layer of SiC 12 is an n-type implanted region, for example, nitrogen or phosphorus ions may be implanted. If, on the other hand the first layer of SiC 12 is a p-type implanted region, for example, Al or boron (B) ions may be implanted.
  • the first layer of SiC 12 may be a p-type epitaxial layer formed on the second surface 10A of a n-type substrate 10.
  • the p-type SiC epitaxial layer 12 may have a carrier concentration of from about 1.0 X 10 16 to about 1.0 X 10 21 cm -3 and a thickness of from about 0.1 to about 20.0 ⁇ m.
  • a mask 100 is formed on the first surface 10B of the substrate 10 and patterned to provide openings corresponding to the p-type well regions provided by the first regions of SiC 14. Suitable dopant ions are implanted in the first surface 10B of the substrate 10 using the mask 100 to provide the first regions of SiC 14.
  • the first region of SiC 14 may be an p-type implanted region provided at the first surface 10B of the p-type substrate 10.
  • the p-type SiC region 14 may have a carrier concentration of from about 1.0 X 10 15 to about 5.0 X 10 19 cm -3 and a thickness of from about 0.3 to about 2.0 ⁇ m.
  • the mask 100 may be removed and a mask corresponding to the JFET region 30 may be provided.
  • a JFET implant may be carried out as described above so as to reduce the spacing between the p-wells 14.
  • the mask 100 of Figure 2B is removed and a second mask 200 is formed on the first surface 10B of the substrate 10 and patterned to provide openings corresponding to the second and fourth regions of SiC 18 and 16.
  • the second and fourth regions of SiC 18 and 16 may be p + regions provided at the first surface 10B of the substrate 10.
  • the second and fourth regions of SiC 18 and 16 may have carrier concentrations of from about 5.0 X 10 17 to about 1.0 X 10 21 cm -3 and thicknesses of from about 0.1 to about 2.0 ⁇ m.
  • the mask 200 of Figure 2C is removed and a third mask 300 is formed on the first surface 10B of the substrate 10 and patterned to provide openings corresponding to the third region of SiC 20.
  • the third region of SiC 20 may be an n + region provided at the first surface 10B of the substrate 10.
  • the third region of SiC 20 may have a carrier concentration of from about 5.0 X 10 17 to about 1.0 X 10 21 cm -3 and a thickness of from about 0.1 to about 1.5 ⁇ m.
  • the resulting structure of Figure 2D may be annealed to activate the dopants.
  • the activation of the dopants may be provided by another processing step, such as by formation of the gate insulator layer or annealing of the ohmic contacts.
  • Figure 2E illustrates the removal of the third mask 300 and formation of the insulator layer 22.
  • the insulator layer 22 may, for example, be grown through thermal oxidation (in which case the depth of the implants may account for the oxidation thickness) and/or may be deposited by, for example, chemical vapor deposition (CVD).
  • the insulator layer 22 may be an oxide grown and/or annealed in NO and/or N 2 O as described above.
  • the insulator layer 22 may be an oxide grown in a nitridating environment.
  • an ONO structure may be provided by thermal oxidation and/or deposition.
  • the gate insulator layer 22 may be formed to a thickness of from about 50 ⁇ to about 4000 ⁇ .
  • metal may be deposited on the insulator layer 22 and patterned to provide the gate electrode 26.
  • the gate electrode 26 may be polysilicon, refractory metal(s) and/or silicide(s). Patterning of the gate electrode 26 may be carried out by masking through photolithography to form an etch mask and etching the gate electrode material using the etch mask, lift-off or other patterning techniques known to those of skill in the art.
  • windows (not shown) corresponding to the ohmic contacts 24 may be opened in the insulator layer 22 corresponding to the contact locations. Accordingly, the contact metal may be deposited in the windows. As seen in Figure 2H , a contact metal is also deposited on the first layer of SiC 12. As discussed above, nickel (Ni) may be deposited for ohmic contacts on n + regions and Al based metal compounds, such Al/Ti, may be deposited for ohmic contacts on P + regions. Once the metals are deposited, the deposited metals may be annealed at temperature from about 500 to about 1200 °C in an inert ambient.
  • the edges of the device may be diced and beveled according to some embodiments of the present invention.
  • Beveling may be performed by, for example, plasma etching or mechanical grinding.
  • a grinding tool 600 may be used to bevel the edges to provide the shape of the structure illustrated in Figure 1 .
  • the edge beveling process may be performed to provide a bevel edge termination structure.
  • a pn blocking junction may be provided between the second surface 10A of the substrate 10 and the first layer of SiC 12. Edge beveling is discussed in detail in Physics of Semiconductor Devices by S. M. Sze at pages 196-198 .
  • a sacrificial oxide layer (not shown) may be formed on the surface of the device and removed to repair any damage to the surface of the device that may have occurred during the edge beveling process.

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  • Manufacturing & Machinery (AREA)
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EP06750425.8A 2005-05-18 2006-04-18 High voltage silicon carbide mos-bipolar devices having bi-directional blocking capabilities and methods of fabricating the same Active EP1882273B1 (en)

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US11/132,355 US7414268B2 (en) 2005-05-18 2005-05-18 High voltage silicon carbide MOS-bipolar devices having bi-directional blocking capabilities
PCT/US2006/014376 WO2006124174A2 (en) 2005-05-18 2006-04-18 High voltage silicon carbide mos-bipolar devices having bi-directional blocking capabilities and methods of fabricating the same

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EP1882273A2 (en) 2008-01-30
JP2008541480A (ja) 2008-11-20
JP5202308B2 (ja) 2013-06-05
TW200701454A (en) 2007-01-01
US20060261347A1 (en) 2006-11-23
US7414268B2 (en) 2008-08-19
WO2006124174A2 (en) 2006-11-23
WO2006124174A3 (en) 2007-04-05

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